Cementitious veneer and laminate material

ABSTRACT

A cementitious veneer and laminate composition is provided. The cementitious laminate composition includes a substrate, a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand; and a cementitious veneer layer applied to the primer layer, the veneer layer comprising a mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst. The polyvinyl alcohol catalyst comprises a mixture of polyvinyl alcohol fibers dissolved in water and mixed with butylene carbonate. The veneer layer is applied to the substrate and primer layer by means including spraying and manual spreading. The veneer layer can be ornamentally manipulated either before or after curing of the veneer layer. The veneer composition can be formed into laminated tiles or panels for use in building applications.

FIELD OF THE INVENTION

[0001] The present invention relates to decorative surface coatings and,more particularly, to durable surface coatings that incorporate acementitious veneer.

DESCRIPTION OF RELATED ART

[0002] Traditional building materials, such as stone, cement, brick, andtile objects have long been valued for both their structural integrityand aesthetic appearance. Since these materials are typically heavy andcumbersome, special measures must often be undertaken to ensure thatobjects and structures made of such materials are properly supported.Unfortunately, not all existing buildings or other structures arecapable of bearing the weight of such objects. Indeed, costly reinforcedframes, reinforced flooring, and so on, are frequently required toensure such support. In some cases, these structures may impose verysignificant costs and require overly complicated building techniques.

[0003] In addition, the material cost of stone, cement, brick, and tile(hereinafter collectively referred to as “masonry”) can also beexpensive. Consequently, economical lighter weight surface coatings thatsimulate the appearance of masonry have been used to enhance theappearance of both utilitarian and decorative objects.

[0004]FIG. 1 is a perspective view of an uncoated surface 10 accordingto the prior art. It is well known in the prior art to apply a surfacecoating or covering to such a surface, for both structural and aestheticpurposes. Examples of common surface coatings that have been made tosimulate the appearance of masonry include vinyl coverings, fabrics,paints, plaster, plastics (e.g., Corian™), and other manufacturedmaterials, such as Formica™. Generally, however, these materials havevarious disadvantages. Vinyl floor and wall coverings usually provide arubbery appearance and are typically recognizable as imitations. Fabricsand paint may be printed or applied in such manner to give a superficialappearance of masonry, but since these materials are quite different ascompared to masonry, they are also often easily detectable asimitations. Moreover, fabrics and paint are relatively delicate and donot withstand a great deal of wear and tear. Plaster may provide abetter approximation of masonry than the above materials, but plaster isrelatively soft, lacks durability and is subject to chipping andcracking. Sheet rock, plaster and gypsum products are also susceptibleto black mold growth that often results when the paper backing used forsuch wallboard products comes into prolonged contact with water ormoisture.

[0005] The search for lightweight durable materials that give theappearance of masonry has lead to the development of masonry-likecoatings that may be applied to suitable foundation materials such aswood, metal, cement fiber boards, or polymeric objects. For example, amethod and apparatus for producing an ornamental concrete surface isdescribed in U.S. Pat. No. 5,502,941. As described therein, anornamental coating which appears as brick or flagstone may consist of awaterproof sub-base of epoxy resin and an elastomeric sealant coveredwith fiberglass webbing. A first mortar layer of cement, sand, colorpigment and aqueous solution of adhesive resin is then sprayed ortroweled on. When the first layer cures, a template having a pattern ofgrout lines is placed over the first layer and a second mortar layerhaving the same composition as the first layer is applied except that acontrasting color is used to give the appearance of grouted brick orflagstones. The ratio of cement to sand is given as fifty-fifty withsolution of acrylic resin varying from one and one-half to two gallonsper 46 pounds bag of dry cement/sand mix.

[0006] In U.S. Pat. No. 5,447,752, a method is described for making adecorative cementitious pattern on a surface. The surface coatingcomposition is described as comprising cement, sand, a polymer binder,and water. The binder is an acrylic latex polymer, such as styrenebutadiene in water. Cement is mixed with sand (30%-40% cement) to form amixture which is combined with the binder solution in an amount rangingfrom two to three gallons binder solution to 100 pounds cement/sand. Thepreexisting surface is etched with muriatic acid, brushed and spraywashed. A template having a desired pattern is placed on the surface anda layer of the surface coating composition is applied into openings inthe template by spraying or by manual spreading.

[0007] U.S. Pat. No. 3,592,724 describes a cementitious laminate ofsulfonated polymers useful for making walls, floors, ceilings andplasterboards having improved water vapor impermeability. As describedtherein, the laminates consist essentially of a surface sulfonated waterinsoluble resinous film and an inorganic cementitious material adheringto at least one surface of the film. In one aspect, hydraulic cement isplastered on a wall and sulfonated film is adhered to the plasteredwall. The laminated wall may be finished with a coat of gypsum plaster.

[0008] In general, present known techniques for producing cementitiouslaminates present certain disadvantages. These include expensive andcomplicated processes, and/or the production of laminates that are heavyand difficult to use and install. A further disadvantage of presenttechniques is that the laminates produced do not feature surfaces thatare sufficiently scratch-resistant, fireproof, or waterproof enough formany industrial or home use environments. Also, available thin cement orconcrete veneers are inherently brittle due to the use of relativelylarge-size aggregates; the use of polymers to counteract the problem ofbrittleness and cracking due to these aggregates often results in aveneer that is overly plastic or resin-like in appearance. A yet furtherdisadvantage associated with present cement and concrete manufacturingmethods is that they are generally very polluting and impose asignificant impact on the environment.

[0009] It is therefore desirable to provide a process that produceseconomical lightweight and durable coatings, which can be used tosimulate the appearance and function of masonry.

[0010] It is further desirable to produce cementitious laminates andveneers that utilize inexpensive and preferably recycled materials thatsatisfy present environmental and sustainability concerns.

[0011] It is yet further desirable to produce a cementitious veneer thatfeatures the use of micro-aggregates to prevent the problem ofbrittleness associated with present thin cement veneers.

[0012] It is also desirable to produce a cementitious veneer that isreadily formable into lightweight transportable panels for use inbuilding applications.

SUMMARY OF THE INVENTION

[0013] A cementitious laminate composition, and method for applying saidcomposition are provided. The cementitious laminate composition includesa substrate, a primer layer applied to the substrate, the primer layercomprising a mixture of polyvinyl alcohol catalyst, Portland cement, andsand; and a veneer layer applied to the primer layer, the veneer layercomprising a mixture of magnesium sulfate, Fillite, magnesium oxide,gypsum cement, and polyvinyl alcohol catalyst. The polyvinyl alcoholcatalyst in the primer and veneer layers comprises a mixture ofpolyvinyl alcohol fibers dissolved in water and mixed with butylenecarbonate. The primer layer is applied to the substrate to provide anadhesive surface that bonds the veneer layer to the substrate. Theveneer layer is applied to the substrate and primer layer by meansincluding spraying and manual spreading. The veneer layer can beornamentally manipulated either before or after curing. The cementitiouslaminate composition can be provided as a kit including the substancesused to form the primer and veneer layers. The veneer composition can beformed into laminated tiles or panels for use in building applications.

[0014] Other objects, features, and advantages of the present inventionwill be apparent from the accompanying drawings and from the detaileddescription that follows below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention is illustrated by way of example and notlimitation in the figures of the accompanying drawings, in which likereferences indicate similar elements, and in which:

[0016]FIG. 1 is a perspective view of an uncoated substrate surfaceaccording to the prior art;

[0017]FIG. 2 is a perspective view of a substrate surface coated with aprimer layer for a cementitious laminate according to one embodiment ofthe invention;

[0018]FIG. 3 is a perspective view of a decorative cementitious veneerlayer applied to a primer layer and substrate according to oneembodiment of the invention;

[0019]FIG. 4 is a perspective view of a decorative cementitious veneerlaminate, according to a first alternative embodiment of the presentinvention; and

[0020]FIG. 5 is a perspective view of a decorative cementitious veneerlaminate, according to a second alternative embodiment of the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0021] Embodiments of the present invention provide a cementitious,masonry-like veneer surface that is economical, lightweight, highlydurable and versatile. The cementitious veneer can be readily providedin a variety of colors and textures. In addition, it can also be shaped,molded, sanded and/or polished to achieve many desired appearances.

[0022] Embodiments of the invention also provide an accurate simulationof the appearance, feel and durability of natural masonry. Thecementitious veneer of the present invention has sufficient strength toresist chipping, gouging and cracking, but is light enough to coverdesired objects without requiring additional support. In addition, thecementitious veneer described herein features advantageous heat andwater resistance characteristics, making it suitable for use in avariety of different building and finishing applications.

[0023] In a preferred embodiment, the cementitious laminate materialdescribed herein comprises a substrate layer coated with an adhesion orprimer layer, onto which is applied a cementitious veneer layer. Thesubstrate provides a firm backing structure for the cementitious veneer,and the adhesion layer helps adhere the cementitious veneer layer to thesubstrate. The cementitious veneer layer comprises the outer layer ofthe cementitious laminate material that features the appearance of anatural masonry material.

[0024] Substrate Layer

[0025] The cementitious veneer can be applied to cover any appropriateunderlying surface on which a masonry-like finish is desired. Theunderlying support surface comprises a substrate, which serves as thebase building material upon which first (primer) and second(cementitious veneer) layers are placed, and in general can be of anyshape, such as flat or curved. For optimum results, the substrate shouldbe a stiff, non-breathable material. FIG. 2 illustrates a substratelayer 10 upon which a first layer 20 is applied.

[0026] In a preferred embodiment of the present invention, the substrate10 comprises a honeycomb structural cardboard, such as Hexacomb™ made byPactiv Corporation. This provides the desired characteristics oflightness, flexibility, strength, and easy installation. Depending uponthe honeycomb size, the strength rating of this substrate can range from8 psi (pounds per square inch) to 60 psi. Other fiber boards can also beused for the substrate, including cement fiberboards, such as plycem™made by U.S. Architectural Products, Inc., and Hardi™ Backboard made byHardi Corporation.

[0027] Other suitable substrate materials include metal, masonry,fiberglass, gypsum board, Masonite®, plastics, ceramic, cement fiberboard, other types of fiber boards, and other common building materials.Wood can also be used as a substrate material, and would preferably be anon-bending hardwood that exhibits satisfactory non-breathingcharacteristics.

[0028] Adhesion/Primer Coat Layer

[0029] As shown in FIG. 2, a first base layer 20 is applied to theunderlying substrate surface 10. For application of this layer, theunderlying substrate surface should be clean and dry. To provide anoptimal bonding surface, the underlying surface can be prepared byetching or sanding. Any method of such surface preparation for bondingknown to those with skill in the art may be used herein.

[0030] This first base layer 20 is an adhesion layer, also referred toas a “primer layer” or “scratch coat” that acts as an undercoating tohelp bond the ultimate cementitious veneer layer to the substrate. Inone embodiment of the present invention, the primer layer comprises amixture of polyvinyl alcohol (PVA) catalyst, Portland cement, and resincoated sand. The mixture is produced by combining, on a volume basis,1.5% to 3.6% Portland cement, 68% to 75% resin coated sand, and 29% to30% polyvinyl alcohol polymer mixed with butylene carbonate in a ratioof 16:1, respectively. The polyvinyl alcohol polymer is produced bydissolving an amount of polyvinyl alcohol fibers in water in anapproximate ratio of one part PVA fibers to 16 parts water. When mixedwith butylene carbonate, the polyvinyl alcohol polymer produces thepolyvinyl alcohol catalyst (PVA catalyst).

[0031] An exemplary formulation which provides an illustration of therelative percentages of these ingredients in the adhesion coat layer isprovided as follows:

[0032] 8 oz. of polyvinyl alcohol polymer mixed 16:1 with butylenecarbonate where the PVA polymer is produced by dissolving 30-40 grams ofPVA fiber in 16-20 oz. of distilled water

[0033] 0.40 to 0.80 oz. Portland cement (e.g., Lehigh™ Portland Cement#1 and #2)

[0034] 15 to 20 oz. resin coated sand (e.g., Borden™ shell process resincoated sand)

[0035] The components of the primer layer are mixed together and appliedto the substrate surface using any appropriate application means, suchas brush, trowel, or spray. Depending upon the size of the batch, curingtime is typically between three to five hours at room temperature. Thiscan be reduced to one to two hours in a controlled heat environment.

[0036] The PVA polymer component of the adhesion layer can be sourcedfrom re-constituted polyvinyl alcohol fibers dissolved in boiling water,preferably distilled water, in an approximate ratio of 16:1. Polyvinylalcohol (PVA) is a reground fiber or waste fiber that is generallyproduced as a by-product in the manufacture of certain medical supplies,such as disposable hospital gowns and hospital bed sheets. As a result,it is an inexpensive material and desirable to use as a recycledmaterial. Polyvinyl alcohol reground fiber, such as is found in theISOLYSER line of products by Orex produced by United Cotton is anexample of an appropriate source of polyvinyl alcohol fibers.Alternatively AIRVOL 125 polyvinyl alcohol can be used in similarconcentrations as that of the recycled PVA fibers.

[0037] The PVA catalyst is produced by mixing the dissolved mixture ofPVA fibers (the PVA polymer) with Jeffsol® butylene carbonate (made byHuntsman Corp.), in a ratio of 16 parts of PVA polymer to one partbutylene carbonate. This serves to strengthen the PVA catalyst'smolecular bond. An exemplary method of producing a sample size of thePVA catalyst is as follows: boil 16 oz. of distilled water, add 40 gramsof polyvinyl alcohol fibers to the boiling water to produce the PVApolymer, allow the PVA polymer to cool and then add 10-15 cc's ofbutylene carbonate to the mixture. For best results, the PVA fibersshould be completely or nearly completely dissolved in the water beforecooling and adding of the butylene carbonate.

[0038] In an alternative embodiment, propylene carbonate can also beused either wholly or in part to replace the Jeffsol butylene carbonate.In this case, the proportion of propylene carbonate may need to beincreased by about 25% over the stated amount of butylene carbonate.

[0039] As shown in the formula provided above, the primer layer alsoincludes a small amount of Portland cement at about 2% to 3% of volume.The Portland cement decreases the slickness of the hardened adhesioncoat layer. The combination of Portland cement and sand createsconcrete, but in this case without much cement, to provide a rough orgritty surface.

[0040] The resin-coated sand represents an aggregate that is added tothe primer/adhesion layer. When used with the PVA catalyst, resin-coatedsand tends to resist absorbing the catalyst. Instead of, or incombination with the resin-coated sand, other aggregates can be used,such as perlite, pumice, vermiculate and man-made pozzalons, and fillitefly ash. Aggregates for use in accordance with the invention areexemplified by a mixture of course and fine relatively inert materials,but may also be of fairly uniform size. Other aggregates that can beused include sand, gravel, silica, glass, crushed stone such as marble,granite, feldspar, basalt, quartz, and so on. However, in a preferredembodiment, resin-coated sand, or other aggregates that exhibit waterand/or oil resistance properties, such as quartz, is used.

[0041] To improve the heat dispersion properties of the cementitiousveneer panel, the adhesion layer can also be impregnated with fillerslike aluminum hydrate, which is a refractory cement. The aluminumhydrate is mixed with the resin-coated sand to create an adhesion layerthat exhibits pronounced heat dispersion characteristics. Theresin-coated sand can also be mixed with other materials, such asperlite, vermiculite, agricultural or regular pumice, or micro-fibercarbon fibers (such as Thermalgraph™ DXDX). These materials also aid inheat dispersion. If any of these optional materials is used for theadhesion layer, the amount of sand can be generally be reduced by acorresponding amount. This aids in reducing the weight of the laminatematerial. If perlite is used, it should first be soaked in the polyvinylpolymer composition, dried and then granulated before it is added to theadhesion layer mixture. This will reduce its tendency to absorb the PVAcatalyst out of the mixture.

[0042] In an alternative embodiment of the present invention, theadhesion layer can be formed using Primus®, which is a materialcommercially available from Dryvit Systems, Inc. Primus® is described bythe manufacturer as containing 54-62% sand, 26-28% water and 9.9-10.2%acrylic latex polymer/binder.

[0043]FIG. 2 is a perspective view of a substrate surface 10 coated witha primer layer according to the invention. The composition for formingthe primer layer 20 is mixed together to form a liquid. This liquid canbe applied by means including spraying or manual spreading, for exampleusing a brush or trowel. The viscosity of the mixture is dependent uponthe concentration of the polyvinyl alcohol catalyst and aggregate (e.g.,resin-coated sand). The viscosity can therefore be adjusted to optimizeapplication to the surface. For example, if application by spraying isdesired, a relatively low viscosity mixture is prepared. A more viscousmixture can be prepared for manual spreading.

[0044] The primer layer mixture is applied to the underlying substratematerial surface prior to curing and hardening. The mixture is thenallowed to cure until hard. The mixture can be applied in amountssufficient to form a layer having a thickness of between approximately{fraction (1/16)} inch and approximately ½ inch, or any other desiredthickness.

[0045] In one embodiment of the present invention, the primer layer caninclude fibers, such as carbon fibers embedded within the layer. Thisincreases the fire and heat resistance of the substrate depending uponthe thickness of the primer layer and the quantity of added fibermaterial. It can also increase the strength of the substrate. Forimproved impact resistance characteristics, materials such as PVA,kevlar, or fiberglass can be added in fiber or mesh form to the adhesionlayer.

[0046] Once dry, the primer layer provides a good adhesive surface forthe second layer (cementitious veneer layer), which is composedprimarily of gypsum cement.

[0047] Cementitious Veneer Layer

[0048] A cementitious veneer layer 30 is applied to the adhesion layer,as illustrated in FIG. 3, to form the cementitious laminate material.This veneer layer provides the look and feel of a concrete or mineralsurface to the lightweight substrate. In one embodiment of the presentinvention, the cementitious veneer layer 30 comprises a mixture ofmagnesium sulfate, magnesium oxide, filler (e.g., Fillite), gypsumcement, and polyvinyl alcohol catalyst, along with other components. Thetwo basic components of the cementitious veneer layer are a magnesiumoxysulfate composition and a cementitious composition. A more detaileddescription of each of these two components will be provided in thedescription that follows.

[0049] The magnesium oxysulfate composition is produced by combining, ona volume basis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17%phosphoric acid at a concentration of 75% to 85%, 47% to 54% magnesiumsulfate, 30% to 35% of magnesium oxide, 1.3% to 1.4% distilled water,and 8% to 11% filler (e.g., Fillite).

[0050] An exemplary formulation which provides an illustration of therelative percentages of these ingredients in the magnesium oxysulfatecomposition is provided as follows:

[0051] 0.20-0.30 oz of sodium hexametaphosphate (sodiumpolymetaphosphate)

[0052] 5 cc-15 cc phosphoric acid at a concentration of 75% to 85%.

[0053] 10 oz.-13 oz. magnesium sulfate (e.g., Epsom salts) in finepowder form

[0054] 3.7 oz-4 oz distilled water

[0055] 8 oz.-10 oz. magnesium oxide

[0056] 3 oz.-5 oz. filler

[0057] The sodium hexametaphosphate is a chelating agent which adheresmagnesium sulfate to magnesium oxide. This is preferably added to 3.7 ozof distilled water and blended at low speed for five to ten minutes. Thephosphoric acid acts to dissolve and evenly disperse the sodiumhexametaphosphate throughout the mixture.

[0058] As shown above, approximately 8% to 11% filler by volume is addedto the magnesium oxysulfate mixture. Fillite 500™ made by TrelleborgFillite Inc. is a preferred ingredient for the filler. For the aboveexemplary mixture this would correspond to about 4.0 oz of Fillite.Fillite is an inert, hollow silicate sphere, or granular fly ash thatacts as an aggregate and increases the strength and water resistance ofthe veneer. The addition of Fillite also tends to enhance the flow andmolding characteristics of the magnesium oxysulfate mixture. The Filliteis added to the mixture until it is hydrated, and the 10 to 13 oz. ofmagnesium sulfate is added to the hydrated Fillite. To this mixture,about 10 oz. of magnesium oxide is added to create the final magnesiumoxysulfate composition.

[0059] With regard to magnesium oxide, Magox™, such as that made byHills Brothers Chemical is a suitable ingredient for use in themagnesium oxysulfate composition. Standard grade Magox is suitable, asis grade 83 WTG. When combined with the salt, this mixture assumes aliquid elastic consistency. The mixture is slowly mixed for severalhours, which is possible due to a relatively long curing time.

[0060] To the above first mixture of the magnesium oxysulfatecomposition is added a second mixture, referred to as the “cementitiouscomposition.” The cementitious composition is produced by mixingtogether, by volume, 1.2% to 1.9% Fillite, 77% to 85% gypsum cement,13.5% to 14% distilled water, and 1.25% to 2.5% of PVA catalyst (made bymixing 16:1 polyvinyl polymer and butylene carbonate). An exemplaryformulation that provides an illustration of the relative percentages ofthese ingredients in the second mixture is provided as follows:

[0061] 0.25 oz Fillite 500, prehydrated with 0.5 oz distilled water

[0062] 11 oz gypsum cement, such as Hydrostone® Super X made by U.S.Gypsum

[0063] 1.8 oz of distilled water

[0064] 5 cc of PVA catalyst, where the PVA catalyst consists of 40 g ofpolyvinyl alcohol fibers boiled in 16 oz distilled water, cooled, thenmixed with 30 cc of butylene carbonate.

[0065] The cementitious composition is a polymer layer that featureswaterproof characteristics. The first and second mixtures are combinedin the following proportions by weight, two parts first mixture(magnesium oxysulfate composition) to 3.25 parts second mixture(cementitious composition). That is, by volume, the magnesium oxysulfatecomposition should constitute 61.5% of the combination. In practice, theratio of magnesium oxysulfate composition could range from 37% to 69%,but it has been found that 61.5% is an optimum ratio. The two mixturesare mixed together for 5-7 minutes at low speed to produce a semi-liquidcomposition that constitutes the cementitious veneer layer mixture. Thecementitious veneer layer 30 can be applied to the adhesion layer 20 bycommon techniques such as brushing or troweling.

[0066] Because magnesium oxide is naturally fire-resistant, themagnesium oxysulfate within the first mixture imparts a fire-resistantcharacteristic to the cementitious veneer. Likewise, the water-resistantnatural properties of Hydrostone Super X when combined with Fillite inthe second mixture imparts a useful water-resistant characteristic tothe cementitious veneer. The PVA catalyst also aids in water-resistance.

[0067] Pigment such as an oxide powder or paste may be added to impart adesired color to the mixture of the cementitious veneer layer 30. Anypigment compatible with cement/gypsum known to those with skill in theart may be used herein.

[0068] During the drying period, the surface of the cementitious veneerlayer may be ornamentally manipulated by means including embossing witha template, pressing, stamping, or carving.

[0069] After the cementitious veneer layer has cured it is generallyfinished, but if desired, it can be further finished by polishingthrough techniques such as wet or dry sanding. The cementitious veneercan be coated on a material which can itself be cut. The cementitiousveneer layer can be cut along with the underlying material. In suchcase, the veneer layer generally does not chip or scratch, and any roughedges can be easily polished if desired.

[0070] As stated above, the primer layer can include fibers, such ascarbon fibers embedded within the layer to increase the fire and heatresistance of the substrate, as well as impact-resistance and strength.Likewise, fibers can also be added to the cementitious layer 30. In oneembodiment of the present invention, fibers added to this layer consistof manufactured Zoltek ½″ chopped fibers B. P. Amoco's ThermalgraphCKDX. Milled fibers, such as Panex 33 MF0200 or Thermalgraph DKDX canalso be used. Poly-vinyl alcohol fibers, such as those made by KurarayCo. can also be used, and are advantageous when used for application inconcrete mixtures, and the RF350×12 mm is a preferable Kuraray fiber.

[0071] In an alternative embodiment of the present invention, thedistilled water used in the cementitious veneer layer can be substitutedwith microclustered water produced through a process described in U.S.Pat. No. 5,711,950, or as described in U.S. Pat. No. 6,033,678. Use ofsuch water has been found to mix more thoroughly and enhance absorptionamong the ingredients in the cementitious veneer layer. Empirically, useof microclustered water has been found to increase the hardness of thecured cementitious veneer layer by up to 100 percent. When used in thecementitious veneer layer, plastic or ceramic mixing blade and bowlsshould be used when mixing microclustered water, since metal surfacescan negatively impact the crystalline structure of the microclusteredwater molecules.

[0072]FIG. 4 illustrates an embodiment of the present invention in whichfibers are embedded within the cementitious veneer layer 40. The surfaceof this layer can be polished so that it is smooth, or it can be leftunpolished to expose the granular pattern of the embedded fibers, as isillustrated in FIG. 4. Prior to curing, the surface of the veneer layer40 can be made to mimic virtually any surface through casting,embossing, or other similar methods. FIG. 5 illustrates an embodiment inwhich fibers are embedded in both the adhesion layer 50 and thecementitious veneer layer 40. The fibers may be carbon fibers or kevlarfibers, glass fibers, or similar types of fibers. For the percentageamounts described above, the amount of fiber used is on the order ofthree to seven grams.

[0073] Instead of fibers, other strengthening materials, such as hempmay be added to either or both of the primer and cementitious veneerlayers. For example, industrial hemp fibers available from Kenex Corp.are suitable types of hemp. To improve mineralization of thereinforcement materials, the hemp may be dipped in a lime solution, suchas slaked lime and water or alcohol. This serves to calcify the hempfibers and improves the texture and uniformity of the cementitiousveneer.

[0074] In addition to the main formula, other fillers and/or substancescan be added to or substituted in varying percentages in thecementitious veneer formula to improve hardness, and water and fireresistance. For example, aluminum hydroxide is an aggregate thatincreases and strengthens the cement matrix of the cementitiouscomposition and is immune to high heated temperatures. Aggregates bynature increase porability, which is also true of aluminum hydroxide.Boric acid is a mild acid that when mixed with gypsum as well aspolyvinyl alcohol creates stronger compounds. Potassium aluminum is asalt, which acts as an accelerator, hardener and fireproofing aid. Whenthese are used together they tend to cancel each other out thereforeproviding the benefit of both without requiring a drying time that iseither too fast or too slow. The amounts recommended for the aboveformula for the cementitious veneer are, 0.20 to 1.00 oz. of aluminumhydroxide, 0.5 to 0.20 oz. of boric acid, and 0.5 to 20 oz. of potassiumaluminum. Certain mineral aggregates, notably quartz, exhibitadvantageous water and oil resistance properties, as well as ornamentalproperties, that may be advantageous for use in the cementitious veneerlayer.

[0075] It should be understood that the embodiments and examplesprovided herein are for purposes of illustration of the invention. It isenvisioned that those with skill in the art can make modifications tothe embodiments and examples provided herein which are within the scopeand spirit of the invention.

[0076] For example, while the above embodiments and examples encompass afirst (primer/adhesion) layer and a second (cementitious veneer) layer,it is contemplated that more than two layers can be applied inaccordance with the present invention. Additional layers of the abovedescribed base mixture can be stacked upon each other. Likewise,additional ornamental layers can be stacked upon each other. Indeed,base layers and ornamental layers can be stacked upon each other inalternating fashion.

[0077] The composition for the cementitious laminate according toembodiments of the present invention can be provided as a kit thatincludes the substances required to form the primer layer and thecementitious veneer layer. Such substances can be pre-mixed, or can besupplied for mixing by the user. The kit can also include containers formixing and storing the primer layer and cementitious veneer mixtures, aswell as means for applying the layers to the substrate surface, such asa trowel.

[0078] In general, panels or tiles can be formed by coating thesubstrate with the adhesion layer and then applying the cementitiousveneer layer within a mold. The mold can be lined with textured orshaped materials to impart an ornamental appearance or functionalcharacteristic to the cementitious veneer panel. For example, a coursetextured mold can impart a rough or serrated surface that aids in gripor traction for the tile. Likewise, if a glossy finish is desired, themold can be lined with a material such as clear vellum. Placing thecementitious veneer layer in contact with the vellum during the curingstep will impart a gloss to the panel. Depending upon the type ofsubstrate material used, the cementitious laminate can also be made intosheets similar to the production of sheet rock.

[0079] In the foregoing, a method for producing a cementitious veneerand laminate has been described. Although the present invention has beendescribed with reference to specific exemplary embodiments, it will beevident that various modifications and changes may be made to theseembodiments without departing from the broader spirit and scope of theinvention as set forth in the claims. Accordingly, the specification anddrawings are to be regarded in an illustrative rather than a restrictivesense.

What is claimed is:
 1. A composition for constructing a cementitiouslaminate, the composition comprising: a substrate comprising a stiffmaterial; a primer layer applied to the substrate, the primer layercomprising a mixture of polyvinyl alcohol catalyst, Portland cement, andsand; and a veneer layer applied to the primer layer, the veneer layercomprising a mixture of magnesium sulfate, filler, magnesium oxide,gypsum cement, and polyvinyl alcohol catalyst.
 2. The composition ofclaim 1, wherein the substrate is selected from the group consisting ofcardboard, wood, metal, masonry, fiberglass, gypsum board, Masonite®,plastics, fiberboard, cement fiberboard, and ceramics.
 3. Thecomposition of claim 1, wherein the primer layer comprises, on a volumebasis, 1.5% to 3.6% Portland Cement, 68% to 75% resin coated sand, and29% to 30% polyvinyl alcohol polymer mixed with butylene carbonate in aratio of 16:1.
 4. The composition of claim 3, wherein the polyvinylalcohol polymer mixed with butylene carbonate is produced by dissolvingpolyvinyl alcohol fibers in boiling distilled water to form a polyvinylalcohol mixture, and mixing the polyvinyl alcohol mixture with butylenecarbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with onepart butylene carbonate.
 5. The composition of claim 1, wherein theveneer layer comprises a first mixture consisting primarily of, on avolume basis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17%phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesiumsulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5%to 3.25% Fillite, and a second mixture comprising primarily, Hydrostone.6. The composition of claim 5, wherein the second mixture comprises, onvolume basis, 1.2% to 1.9% Fillite, 77% to 85% Hydrostone Super X, 13.5%to 14% distilled water, and 1.25% to 2.5% of the 16:1 mixture ofpolyvinyl polymer and butylene carbonate.
 7. The composition of claim 6,wherein the mixture of polyvinyl alcohol polymer and butylene carbonateis produced by dissolving polyvinyl alcohol fibers in boiling distilledwater to form a polyvinyl alcohol mixture, and mixing the polyvinylalcohol mixture with butylene carbonate, in a ratio of 16 parts ofpolyvinyl alcohol mixture with one part butylene carbonate.
 8. Thecomposition of claim 7, wherein the first mixture and second mixture arecombined in a ratio of one part first mixture to one and one-half partssecond mixture.
 9. The composition of claim 6, wherein the veneer layerfurther comprises embedded fibers to increase a strength characteristicof the cementitious laminate.
 10. The composition of claim 6, whereinthe veneer layer further comprises pigment or stains to enhance anappearance characteristic of the cementitious laminate.
 11. Thecomposition of claim 6, wherein the veneer layer is ornamentallymanipulated prior to drying.
 12. The composition of claim 4, whereinprimer layer is applied to the substrate to form an adhesion layer forthe veneer layer, the primer layer having a thickness of betweenapproximately {fraction (1/16)} inch and approximately ½ inch.
 13. Amethod of constructing a constructing a cementitious laminate,comprising the steps of: providing a substrate comprising a stiffmaterial, wherein the substrate is selected from the group consisting ofcardboard, wood, metal, masonry, fiberglass, gypsum board, Masonite®,plastics, fiberboard, cement fiberboard, and ceramics; applying a primerlayer to a surface of the substrate, the first layer comprising amixture of polyvinyl alcohol catalyst, Portland cement, and sand; andapplying a veneer layer to the primer layer, the veneer layer comprisinga mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement,and polyvinyl alcohol catalyst.
 14. The method of claim 13 furthercomprising the step of combining, on a volume basis, 1.5% to 3.6%Portland Cement, 68% to 75% resin coated sand, and 29% to 30% polyvinylalcohol polymer mixed with butylene carbonate in a ratio of 16:1 to forma wet composition for the primer layer, wherein the polyvinyl alcoholpolymer mixed with butylene carbonate is produced by dissolvingpolyvinyl alcohol fibers in boiling distilled water to form a polyvinylalcohol mixture, and mixing the polyvinyl alcohol mixture with butylenecarbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with onepart butylene carbonate.
 15. The method of claim 14, further comprisingthe step of combining a first layer consisting primarily of, on a volumebasis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17%phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesiumsulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5%to 3.25% Fillite, and a second mixture comprising primarily, HydrostoneSuper X.
 16. The method of claim 15, wherein the second mixture isproduced by combining, on volume basis, 1.2% to 1.9% Fillite, 77% to 85%Hydrostone Super X, 13.5% to 14% distilled water, and 1.25% to 2.5% ofthe 16:1 mixture of polyvinyl polymer and butylene carbonate, whereinthe mixture of polyvinyl polymer and butylene carbonate is produced bydissolving polyvinyl alcohol fibers in boiling distilled water to form apolyvinyl alcohol mixture, and mixing the polyvinyl alcohol mixture withbutylene carbonate, in a ratio of 16 parts of polyvinyl alcohol mixturewith one part butylene carbonate.
 17. The method of claim 16 furthercomprising the step of combining the first mixture and the secondmixture in a ratio of one part first mixture to one and one-half partssecond mixture.
 18. The method of claim 16, further comprising the stepof embedding fibers within the veneer layer to increase a strengthcharacteristic of the cementitious laminate.
 19. The method of claim 16,further comprising the step of adding pigment to the veneer layer toenhance an appearance characteristic of the cementitious laminate. 20.The method of claim 16, further comprising the step of ornamentallymanipulating the veneer layer prior to drying.
 21. The method of claim13 further comprising the steps of: applying the primer layer to thesubstrate to form an adhesion coat of approximately {fraction (1/16)}inch and approximately ½ inch thick; allowing the adhesion coat to atleast partially cure; applying the veneer layer to the adhesion coatafter the at least partial curing of the adhesion coat; and forming thecementitious laminate into tiles.
 22. A cementitious laminatecomprising: a substrate comprising a stiff material, the substrate beingselected from the group consisting of cardboard, wood, metal, masonry,fiberglass, gypsum board, Masonite®, plastics, fiberboard, cementfiberboard, and ceramics; a primer layer applied to the substrate, theprimer layer comprising a mixture of polyvinyl alcohol catalyst,Portland cement, and sand; and a veneer layer applied to the primerlayer, the veneer layer comprising a mixture of magnesium sulfate,filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst.23. The cementitious laminate of claim 22, wherein the primer layercomprises, on a volume basis, 1.5% to 3.6% Portland Cement, 68% to 75%resin coated sand, and 29% to 30% polyvinyl alcohol polymer mixed withbutylene carbonate in a ratio of 16:1, wherein the polyvinyl alcoholpolymer mixed with butylene carbonate is produced by dissolvingpolyvinyl alcohol fibers in boiling distilled water to form a polyvinylalcohol mixture, and mixing the polyvinyl alcohol mixture with butylenecarbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with onepart butylene carbonate to create the polyvinyl alcohol catalyst. 24.The cementitious laminate of claim 23, wherein the veneer layercomprises a first mixture consisting primarily of, on a volume basis,0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17% phosphoric acidat a concentration of 75% to 85%, 40% to 46% magnesium sulfate, 30% to35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5% to 3.25%Fillite, and a second mixture comprising, on volume basis, 1.2% to 1.9%Fillite, 77% to 85% Hydrostone Super X, 13.5% to 14% distilled water,and 1.25% to 2.5% of the 16:1 mixture of polyvinyl polymer and butylenecarbonate.
 25. The cementitious laminate of claim 24, wherein themixture of polyvinyl alcohol catalyst is produced by dissolvingpolyvinyl alcohol fibers in boiling distilled water to form a polyvinylalcohol mixture, and mixing the polyvinyl alcohol mixture with butylenecarbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with onepart butylene carbonate.
 26. The cementitious laminate claim 25, whereinthe first mixture and second mixture are combined in a ratio of one partfirst mixture to one and one-half parts second mixture.
 27. Thecementitious laminate of claim 22, wherein the veneer layer furthercomprises at least one of: embedded fibers to increase a strengthcharacteristic of the cementitious laminate, and pigment to enhance anappearance characteristic of the cementitious laminate.
 28. Acementitious veneer comprising: a magnesium oxysulfate compoundincluding magnesium sulfate, magnesium oxide, sodium hexametaphosphate,phosporic acid, and water; and a cementitious composition mixed with themagnesium oxysulfate compound to form a cementitious veneer mixture, thecementitious composition including gypsum cement, filler, water, and apolyvinyl alcohol polymer mixture.
 29. The cementitious veneer of claim28 wherein the polyvinyl polymer mixture comprises polyvinyl alcoholfibers boiled in water with butylene carbonate.
 30. The cementitiousveneer of claim 29 wherein the water is distilled water.
 31. Thecementitious veneer of claim 29 wherein the water is microclusteredwater.
 32. The cementitious veneer of claim 29 wherein the magnesiumoxysulfate compound comprises approximately sixty percent of thecementitious veneer mixture.
 33. The cementitious veneer of claim 28,wherein the magnesium oxysulfate compound consists of, on a volumebasis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17%phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesiumsulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5%to 3.25% Fillite, and the cementitious composition consists of, onvolume basis, 1.2% to 1.9% Fillite, 77% to 85% Hydrostone Super X, 13.5%to 14% distilled water, and 1.25% to 2.5% of the 16:1 mixture ofpolyvinyl polymer and butylene carbonate.
 34. A cementitious veneercomprising a cementitious composition mixed with a magnesium oxysulfatecompound to form a cementitious veneer mixture, the magnesium oxysulfatecompound consisting of, on a volume basis, 0.04% to 0.08% sodiumhexametaphosphate, 0.06% to 0.17% phosphoric acid at a concentration of75% to 85%, 40% to 46% magnesium sulfate, 30% to 35% magnesium oxide,1.3% to 1.4% distilled water, 2.5% to 3.25% Fillite, and thecementitious composition consisting substantially of Fillite.